System and process for installing a temporary tile floor surface

ABSTRACT

A process for installing a temporary tile floor surface includes identifying a substrate surface requiring installation of the temporary tile floor surface. The process further includes installing a dampened tile system including a dampening material between a bottom surface of tiles of the dampened tile system and the substrate surface.

CROSS REFERENCE TO RELATED APPLICATIONS

This disclosure is a continuation-in part of U.S. application Ser. No.28/658,996 filed on Mar. 17, 2017, and this disclosure is acontinuation-in-part application of U.S. application Ser. No. 14/695,203filed on Apr. 24, 2015 which claims the benefit of U.S. ProvisionalApplication No. 61/984,105 filed on Apr. 25, 2014, all of which arehereby incorporated by reference.

TECHNICAL FIELD

This disclosure is related to use of a floor tile for use in newconstruction or renovation. In particular, this disclosure is related toa tile with beneficial properties in applications wherein a substratecan be unstable and/or noise dampening or thermal insulation isdesirable. Additionally, the disclosure is related to a tile for usewhen a temporary flooring material might be desired or a floor with theability renew and replace easily with no messy or common constructionprocesses would be associated with the replacement process.Additionally, the disclosure is related to a tile for use with a simpleinstallation in which almost no prior experience would be required tocomplete a satisfactory installation in a floor application.

BACKGROUND

The statements in this section merely provide background informationrelated to the present disclosure. Accordingly, such statements are notintended to constitute an admission of prior art.

Tile is widely used as a decorative and functional material for use inresidential and commercial buildings. Tile provides a finished look, andit also is easier to clean in some applications than other types ofcovering materials. Tile construction typically includes a porcelain orceramic tile adhered to a substrate surface with an adhesive, andborders surrounding the tile are filled with grout. Such typical tileconstruction is rigid and durable when it is stable. However, asubstrate can be less than perfectly stable. If a substrate flexes orshifts or people or objects move across the floor, grout and/or theadhesive binding the tile to the floor can crack and break, leading toloose or broken tiles.

Standard tile configurations include rigid grout adhering tile tosubstrate. Such rigid grout easily transmits sound waves from the tileto the substrate and vice versa. Similarly, rigid grout rigidly holdsthe tile in place. In the event the substrate is uneven or flexible,both the tile and the grout itself are subject to breakage andaccelerated wear when weight is applied to the tile.

SUMMARY

A process for installing a temporary tile floor surface includesidentifying a substrate surface requiring installation of the temporarytile floor surface. The process further includes installing a dampenedtile system including a dampening material between a bottom surface oftiles of the dampened tile system and the substrate surface.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments will now be described, by way of example, withreference to the accompanying drawings, in which:

FIG. 1 illustrates a bottom side of an exemplary encapsulated tile, inaccordance with the present disclosure;

FIG. 2 illustrates a top side of the encapsulated tile of FIG. 1, inaccordance with the present disclosure;

FIG. 3 illustrates an alternative exemplary embodiment of tile utilizinga coating of closed-cell foam on a bottom surface of the tile, inaccordance with the present disclosure;

FIG. 4 illustrates an alternative exemplary embodiment of tile utilizinga coating of closed-cell foam to create a border around the tile, inaccordance with the present disclosure;

FIG. 5 illustrates an alternative exemplary embodiment of tile utilizinga closed-cell foam appliqué to dampen the tile, in accordance with thepresent disclosure;

FIG. 6 illustrates an alternative exemplary embodiment of tile utilizingthe bordered tile of FIG. 4 in combination with a sheet of dampeningmaterial between the tile and the substrate, in accordance with thepresent disclosure;

FIG. 7 illustrates exemplary removal of a first set of dampened tilesand simultaneous installation of a second set of dampened tiles, inaccordance with the present disclosure;

FIG. 8 illustrates an exemplary tile configuration including transitionsto another floor surface and a wall surface, in accordance with thepresent disclosure;

FIG. 9 illustrates through a flow chart an exemplary process forinstalling a temporary tile floor with dampened tiles, in accordancewith the present disclosure;

FIG. 10 illustrates through a flow chart an exemplary process forinstalling a temporary tile floor with a layer of dampening materialinstalled under the tiles, in accordance with the present disclosure;

FIG. 11 illustrates through a flow chart an exemplary process forinstalling a temporary tile floor with dampened tiles and a layer ofdampening material installed under the tiles, in accordance with thepresent disclosure;

FIG. 12 illustrates a prior art tile placed upon a substrate including abump upon the substrate, the tile placed upon the substrate without anygrout, in accordance with the present disclosure;

FIG. 13 illustrates the prior art tile of FIG. 12, with a crack formingin the tile, in accordance with the present disclosure; and

FIG. 14 illustrates the dampened tile of FIG. 2 placed upon a substrateincluding a bump upon the substrate, with the dampening material of thetile deforming to permit the tile to lay flat upon the substrate inspite of the bump, in accordance with the present disclosure.

DETAILED DESCRIPTION

Porcelain tile and ceramic tile are a rigid materials. When stablysupported, the tile can be strong and durable. If the floor or slabunder the tile moves, shifts, or is otherwise unstable, movement betweenthe tile and the floor can damage the tile, the adhesive between thetile and the floor, and the grout surrounding the tile.

A dampened tile is provided utilizing a dampening material applied tolower surfaces if the tile. In one embodiment, the dampened tile is anencapsulated tile, with all sides of the tile coated in the dampeningmaterial except the visible surface of the tile. The dampening materialcan be provided upon the tile at a manufacturing location and shippedand sold to the consumer with the dampening material pre-applied. Inother embodiments, the dampening material can cover only the sides oronly the bottom of the tile. In other embodiments, the dampeningmaterial can be applied away from the manufacturing site or by theconsumer. In other embodiments a dampening layer of material can be usedin place of or in addition to dampening material applied to the tile.

Exemplary dampened or encapsulated tiles of the disclosure, onceinstalled, resist breakage due to non structural slab movement, theyfeel softer under foot, they feel warmer than hard set tile floors, lesssound is transferred to below living spaces and in the same room. Thedampened tiles are easy to install and care for. Using the tiles createsa forgiving system, if an installation error is made or an event evertakes place that would require removal of the tiles this can be doneeasily and tiles can be replaced once the issue has been corrected.

The disclosed tiles are suitable for residential or light commercialinstallations, defined as areas where the system is subject to foottraffic or light pneumatic wheeled carts. However, flex and dampeningproperties provided by the disclosed system can cause force that wouldnormally be distributed across an entire tile or a plurality of tiles tobe concentrated on a portion or point of a tile. Care should be taken toavoid using the tile where hard metal or plastic solid wheel carts areutilized. Similarly, heavy point loads exceeding the tiles expectedbreaking strength requirements should be avoided. The disclosed tilesystem is not suitable for forklift, pallet jacks, or wheeled traffic ofheavy loads or other areas whereby the tiles will be subject to extraheavy load requirements. Care should be taken not to exceed loadrequirements specified by manufacturers of tiles used or coated asdisclosed.

In some embodiments, tiles utilized should be of the highest qualityimpervious porcelain body, less than 0.5% absorption tested under ASTMtest methods. In one embodiment, tiles must be a thickness of 9.5 mm(⅜″) or greater. In one embodiment, tile thickness between 10 and 12 mmis recommended. Under some conditions, tile with small or no deviationin thickness within the tile provide best results. Exemplary tiles foruse with the disclosed system should be flat in all aspects, across theface and edges with no wedging or warpage. Such exemplary tiles shouldbe first quality under ANSI A137.1-2008. Under some conditions, alledges should be rectified to provide strait 90 degree edges and a singlecalibration per lot size.

A floor substrate must be clean and free of debris in preparation forinstallation. Any floor suitable for a standard thinset application oftile are acceptable with the following restrictions. Floors must be flatand not have deflection greater than ⅛″ in 10 feet. There must be notransitional heights or structural defects to be bridged which wouldallow upward or other unstable movement under the tiles. The tiles mustbe tight fit within the field of tiles and at all edges to restrictmovement. Use of high quality silicone can be utilized at the outsideedges of the tiles to restrict movement of the tiles where there is nowall structure or other edge surface containing the outside tiles. Onecan use metal or other tile edging transitions known in the art totransition from the tiles. One may bond transitions to the floor to holdtiles firm on their edges. Glue transitions to the floor to hold tilesfirm on edges are recommended, with double stick carpet tape or epoxybond transition strips.

Tiles may be cut to size. One may use scoring tools or a wet sawaccording to normal tile cutting practice.

Cutting, with scoring tools or wet saw, can be used as are known in theart to cut tiles.

Care of the tiles can be performed according to a number of envisionedprocesses. Edges may be heat sealed to enhance water perm performance.Mop tiles with light mopping is recommended, as flooding surface shouldbe avoided. If flooding has taken place, and water or cleaner removal isdesired pick-up tiles, clean or dry then reset. If heavy cleaning isrequired to remove contaminants from below the surface of the tiles,pick-up those affected tiles and clean and replace. For care of thespecific tiles, one may follow manufacturers recommended instructions.

FIG. 1 illustrates a bottom side of an exemplary encapsulated tile.Dampened and encapsulated tile 10 is illustrated. As disclosed herein,an encapsulated tile is coated on five of the six surfaces of a tile,with the bottom and the four thin side surfaces coated. Coating 20 isillustrate applied to the named sides of tile 30. Coating 20 isillustrated as a thick coating in FIG. 1 and throughout the disclosure,for example, visually comparable to the thickness of the tile. Thisthickness is for illustration and clarity purposes. In manycircumstances, the layer will actually be thin, for example between 1 mmand 5 mm, depending upon the particular dampening material used and thedesired application for the tiles.

Dampening materials or coatings as disclosed herein can take any of anumber of embodiments. Closed-cell foam, such as exemplary ethylenepropylene diene terpolymer (EPDM), is one exemplary product that can beutilized. Open-cell foam is another exemplary product that can beutilized. A rubberized layer or polymerized spray on coating canadditionally be utilized. A desirable dampening material is durable andcan accept the loading and temperature ranges seen in normal flooringapplications. Such a material meets all regulations and codes for safeuse around persons. Such a material tends to be flexible, providingelasticity even after the tile is installed to a surface and abutted toother neighboring tiles. Such a material holds up to light cleaning andmopping without absorbing water or other liquids.

According to one exemplary embodiment of dampening materials, Nittoprovides 5790S-series dampening tapes, which are single coated foamtapes These dampening tapes are based on a cross linked polyolefin foam,coated with pressure sensitive adhesive, and having excellent bondingproperties, especially on low energy surfaces. In one embodiment, thetape includes a polyolefin foam carrier top layer, a modified acrylicadhesive middle layer, and a paper release liner bottom layer. Nitto5790S-series are single-coated foam tapes known in the art withexcellent adhesion properties on a wide range of materials such asplastic, steel, and glass. The flexible foam carrier conforms easy tothe irregularities of the substrate and provides impact resistance,thermal insulation, sound dampening and sealing properties. Nitto5790S-series tapes are used in other applications as a gap filler toabsorb sound and to seal against dust and humidity. Exemplary tapethicknesses include 0.6 mm and 1.1 mm.

FIG. 2 illustrates a top side of the encapsulated tile of FIG. 1.Encapsulated tile 10 is illustrated including dampening material 20 andtop surface 12 of tile 30 being visible without any dampening coating.

FIG. 3 illustrates an alternative exemplary embodiment of tile utilizinga coating of closed-cell foam on a bottom surface of the tile. Dampenedtile 100 is illustrated including tile 30 and dampening coating 40applied to a bottom side 35 of tile 30. Coating 40 dampens contactbetween tile 30 and the substrate surface. Once applied to a floorsurface, any suitable flexible caulking material can be used to fillgaps between tile 30 and adjacent tiles.

FIG. 4 illustrates in cross-section an alternative exemplary embodimentof tile utilizing a coating of closed-cell foam to create a borderaround the tile. Bordered tile 200 is illustrated including tile 30bounded on all four thin sides 38 of tile 30 by dampening coating 50. Inone embodiment, such a bordered tile would be beneficial as being easierto ship than an encapsulated tile. Any dampening material could be laterapplied to the tile or to the substrate to enable bordered tile 200 toperform according to the disclosed tile system.

FIG. 5 illustrates an alternative exemplary embodiment of tile utilizinga closed-cell foam appliqué to dampen the tile. Tile 30 is illustrated,initially provided as an unmodified tile. Appliqué 250 is illustrated,constructed of a dampening material and ready to apply to a bottom sideof tile 30. Appliqué 250 is envisioned to take any number of forms,including a layer of closed cell foam applied to a thin sheet ofadhesive paper. In another embodiment, appliqué 250 can take the form ofa sprayed on rubberized material.

One exemplary particular appliqué can include a particular version ofthe Nitto 5790S-series dampening tape, disclosed herein. Nitto 5790S10foam is provided in an exemplary 1300 mm width. In accordance with thepresent disclosure, this material can be provided as a flat foam productwith adhesive pre-applied to the foam with pull-away paper backingpreserving the adhesive prior to attachment to the tile. The 1300 mmwide product can be easily cut to size for application to the tile. Thisparticular tape is exemplary of foam tape that can be utilized accordingto the disclosure, although a number of different foam tapes and othermaterials can be similarly used. The disclosure is not intended to belimited to the particular examples provided

FIG. 6 illustrates an alternative exemplary embodiment of tile utilizingthe bordered tile of FIG. 4 in combination with a sheet of dampeningmaterial between the tile and the substrate. Embodiments are disclosedherein wherein dampening material is applied to individual tiles. FIG. 6illustrates and exemplary separate layer 300 of dampening material thatdoes not need to be applied to each individual tile. Layer 300 can beapplied to substrate 310 before bordered tile 200 is installed Tileswithout any dampening material can be utilized with layer 300, forexample, with a flexible caulking material applied after the tiles areplaced upon layer 300. Encapsulated tiles can be used, installed abovelayer 300. In FIG. 6, a bordered tile 200 including tile 30 surroundedin all four thin sides with dampening material is illustrated.

FIG. 7 illustrates exemplary removal of a first set of dampened tilesand simultaneous installation of a second set of dampened tiles. Tiles30 a illustrate a first color of tile. Tiles 30 b illustrate a secondcolor of tile. Tiles 30 a and 30 b can be coated or encapsulated withthe disclosed materials to dampen the tiles. Alternatively oradditionally, a layer or sheet of dampening material may be installedupon substrate 310 prior to the installation of the tiles. Due to theease of installation and removal of the tiles, for example, utilizing asuction handle device 350 to selectively adhere to the top surfaces ofthe tiles, one may conveniently remove tiles 30 a and replace them withtiles 30 b. Without having to tear away grout and adhesive from thesubstrate, a user can easily change one set of tiles for another set. Atemporary display at a trade show or in a mall kiosk can convenientlyinclude an seemingly permanent tile floor which can easily be removedwhen the event is over. A hotel can change tile patterns on the lobbyfloor based upon a season or a particular event being held at the hotel.A home owner could easily set down different tile in a bathroom orkitchen based upon dinner company or houseguests. The dampened tiledisclosed herein provide for easy installation and removal of the tile.The flexible dampening material on the tile or sheet under the tileprovide stability and durability to the tiles in use without the use oftraditional grout and adhesives.

FIG. 8 illustrates an exemplary tile configuration including transitionsto another floor surface and a wall surface. Tiles 30 including coatings20 are illustrated applied to exemplary rubberized dampening sheet 300upon substrate 310. Coatings 20 are illustrated on the bottoms and leftand right sides of tiles 30, as illustrated. A coating 20 couldadditionally be included on the visible thin front sides of tiles 30. Aneighboring floor surface 360 is illustrated. Floor surface 360 is inthis example inadequate to contain tiles 30 bordering floor surface 360.In order to keep tiles directly bordering surface 360 stationary andstable, adhesive 380 can be applied at the transition between tile 30and substrate 310. Additionally, a neighboring wall surface 372 isillustrated. Exemplary border trim 370 is illustrated mounted above tile30 at the transition with wall surface 372. As a result of thestabilizing effect of trim 370, no adhesive 380 may be necessary at thetransition between tiles 30 and wall surface 372. Adhesive 380 caninclude silicone or a similar substance preventing water intrusion atthe transition. Similar transitions and use of stabilizing adhesive orsilicone are envisioned, and the disclosure is not intended to belimited to the particular examples provided herein.

The disclosed tile system enables use of a temporary displayconstruction method in accordance with the disclosure. Any merchant mayquickly and inexpensively set up a temporary tile floor that seems to bea permanent construction. Exemplary show booths can be set up forexhibitions, outdoor markets, and fairs. The result is an easy to clean,durable, hygienic temporary surface. An exemplary restaurant, coffeeshop, or bar could set up flooring on a sidewalk or parking lot for aone day summer fair or sporting event, providing customers with aprofessionally crafted tile floor, and then the temporary floor can beeasily removed after the event. An exemplary bar could set up a tilesurface on an outside wooden deck. A restaurant with a damaged floorcould place the disclosed tile system over the damaged floor until therepairs can be arranged in order to remain open in the meantime. Anumber of exemplary uses of the disclosed system are envisioned, and thedisclosure is not intended to be limited to the examples provided.

An exemplary process for installing a temporary floor for a booth or atemporary kiosk includes selecting a sufficiently flat substratesurface; thoroughly cleaning the flat surface; applying a rubberized orpolymerized sheet (if one is being used in addition to or in thealternative to a tile with dampening material applied to the bottom ofthe tile;) laying down untreated tile upon the sheet or laying downtreated dampened tile according to the disclosure; securing side tilesof the floor pattern (using an adhesive such as silicone or using atransition bracket or transition strip;) using and cleaning the surfacefor the commercial event or activity; removing the tile and associatedtransition materials; removing the sheet from the substrate if applied;and cleaning the substrate surface according to methods known in theart.

In addition to commercial uses, the disclosed tile system can be used intemporary, permanent, or semi-permanent residential flooringapplications. For example, the disclosed tile system could be used onoutdoor and backyard to cover a cement patio or a wood deck or even agrass area (meeting the flatness requirements) around pools and gazebos.If a wedding reception were being held at a house, an outside patiocould be turned into a tent area with a fine tile floor which could beremoved the next day. If a kitchen floor includes a fairly flexiblewooden surface that would cause normal grout to crack and fail undernormal use, the disclosed tile could be used to provide a tile surfaceover the wooden surface. A number of exemplary uses of the disclosedsystem are envisioned, and the disclosure is not intended to be limitedto the examples provided.

The disclosed tile system, in several exemplary embodiments, is easy toinstall, temporary, reusable, or reusable flooring that may be removedshortly after being installed or may not ever be removed. Unlikeanything else on the market, people may want the floating floor fortheir permanent flooring because it is easy to install, but knowing theycan later remove for fashion change, in a water event like a flood, etc.. . . it allows removal, drying and replacement of the flooring, sellthe house take your flooring with you. No adhesive, grout, side grovesor click system is required. The user can lay the tile as disclosed andallow damping material to provide movement and edge stability betweenthe tiles and the subfloor.

Whereas undampened tile laid upon a substrate such as a flat concretesurface, due to small inconsistencies in the tile or the substrate,would be prone to movement, rocking, and cracking, use of a dampenedtile or a sheet of dampening material permits the improved tile to layflat upon the substrate in spite of the inconsistencies. FIG. 12illustrates a prior art tile placed upon a substrate including a bumpupon the substrate, the tile placed upon the substrate without anygrout. Tile 700 is laid upon substrate 710. Substrate 710 is illustratedincluding bump 705 representing an inconsistency that prevents a bottomsurface of tile 700 from laying flat upon substrate 710. Because tile700 of FIG. 12 does not lay flat upon substrate 710, the tile is proneto movement, rocking, and/or cracking as weight is applied to a topsurface of the tile. FIG. 13 illustrates the prior art tile of FIG. 12,with a crack forming in the tile. Tile 700 is illustrated laid uponsubstrate 710 including bump 705. Crack 715 has formed in tile 700, aspedestrian traffic or other weight applied to a top of tile 700 brokethe tile.

FIG. 14 illustrates the dampened tile of FIG. 2 placed upon a substrateincluding a bump upon the substrate, with the dampening material of thetile deforming to permit the tile to lay flat upon the substrate inspite of the bump. Tile 30 is illustrated including dampening material20 applied to the thin sides and a bottom surface of tile 30. Tile 30 islaid upon substrate 810 including bump 805. The illustration includesmagnified portion 802, illustrating bump 805 displacing a portion ofdampening material 20. Because the dampening material can deform anddisplace away from bump 805, tile 30 lays flat upon substrate 810 inspite of bump 805.

FIG. 9 illustrates through a flow chart an exemplary process forinstalling a temporary tile floor with dampened tiles. Process 400starts at step 402. At step 404, a conforming sub-surface or substratearea, for example, meeting criteria for flatness, is identifiedrequiring tile installation. At step 406, the sub-surface area iscleaned to remove excess inconsistencies. At step 408, a tile with adampening coating upon a bottom side of the tile is installed over thesub-surface area. Step 408 is repeated over and over again until thearea is covered with dampened tiles. At step 410, an exemplary eventwhich prompted installation of the tile is held. At step 412, thedampened tiles are picked up one by one until the sub-surface area isexposed. At step 414, the process ends.

FIG. 10 illustrates through a flow chart an exemplary process forinstalling a temporary tile floor with a layer of dampening materialinstalled under the tiles. Process 500 starts at step 502. At step 504,a conforming sub-surface or substrate area, for example, meetingcriteria for flatness, is identified requiring tile installation. Atstep 506, the sub-surface area is cleaned to remove excessinconsistencies. At step 508, a sheet of dampening material, forexample, including foam sheet according to the disclosure, is laid uponthe sub-surface. At step 510, an unimproved tile is installed over thedampened sheet. Step 510 is repeated over and over again until the areais covered with tiles. At step 512, an exemplary event which promptedinstallation of the tile is held. At step 514, the tiles are picked upone by one until the sheet is exposed. At step 516, the sheet ofdampening material is picked up. At step 518, the process ends.

FIG. 11 illustrates through a flow chart an exemplary process forinstalling a temporary tile floor with dampened tiles and a layer ofdampening material installed under the tiles. Process 600 starts at step602. At step 604, a conforming sub-surface or substrate area, forexample, meeting criteria for flatness, is identified requiring tileinstallation. At step 606, the sub-surface area is cleaned to removeexcess inconsistencies. At step 608, a sheet of dampening material, forexample, including foam sheet according to the disclosure, is laid uponthe sub-surface. At step 610, a tile with a dampening coating upon abottom side of the tile is installed over the sub-surface area. Step 610is repeated over and over again until the area is covered with dampenedtiles. At step 612, an exemplary event which prompted installation ofthe tile is held. At step 614, the dampened tiles are picked up one byone until the sub-surface area is exposed. At step 616, the sheet ofdampening material is picked up. At step 618, the process ends.

The disclosure has described certain preferred embodiments andmodifications of those embodiments. Further modifications andalterations may occur to others upon reading and understanding thespecification. Therefore, it is intended that the disclosure not belimited to the particular embodiment(s) disclosed as the best modecontemplated for carrying out this disclosure, but that the disclosurewill include all embodiments falling within the scope of the appendedclaims.

1. A process for installing a temporary tile floor surface, comprising:identifying a substrate surface requiring installation of the temporarytile floor surface; and installing a dampened tile system comprising adampening material between a bottom surface of tiles of the dampenedtile system and the substrate surface.
 2. The process of claim 1,wherein installing the dampened tile system comprises installing thetiles comprising a dampening material adhered to the bottom surface ofthe tiles.
 3. The process of claim 1, wherein installing the dampenedtile system comprises installing a sheet of dampening material betweenthe tiles and the substrate surface.
 4. The process of claim 3, whereininstalling the dampened tile system further comprises installing thetiles, each tile comprising a dampening material adhered to at least onesurface of the tile.
 5. A process for installing a temporary tile floorsurface, comprising: identifying a substrate surface requiringinstallation of the temporary tile floor surface; and laying dampenedtiles comprising a ceramic tile and a dampening material adhered to abottom surface of the ceramic tile upon the substrate surface.
 6. Aprocess for installing a temporary tile floor surface, comprising:identifying a substrate surface requiring installation of the temporarytile floor surface; and laying dampened tiles comprising a ceramic tileand a dampening material adhered to a bottom surface and at least onethin side surface of the ceramic tile upon the substrate surface.